Method of knitting hoisery blanks



March 25, 1969 w. J. BARBEE METHOD OF KNITTING HOSIERY BLANKS Sheet Filed July 24, 1968 INVENTORI WALTER l'. BARBIE-:-

ATTORNEYS March 25, 1969 w. .1. BARBEE METHOD OF KNITTING HOSIERY BLANKS Filed July 24, 1968 ATTORNEY 5 United States Patent O U.S. Cl. 66-149 7 Claims ABSTRACT F THE DISCLOSURE A seamless hosiery blank is knit on a circular knitting machine in such a manner that the tubular blank is withdrawn from the machine in an everted (inside-out) condition. This eversion is accomplished by holding the initially knit end of the hosiery blank on the dial instrumentalities of the knitting machine while knitting the desired length of blank on the cylinder needles, releasing the terminal end of the blank from the cylinder needles to permit the blank to unfold and assume the everted condition, and then releasing the initially knit end of the blank from the dial instrnmentalities and withdrawing the blank in the everted condition.

This invention relates generally to a method of knitting seamless hosiery blanks on a circular knitting machine and more particularly to a method whereby the hosiery blank is withdrawn from the machine in everted condition.

Seamless hosiery blanks are normally knit in a rightside-out condition on a circular knitting machine and upon the completion vof the knitting operation, the blank is withdrawn in this `right-side-out condition. The hosiery blanks are then everted in a separate operation so that the toe end of the blank may be closed, by looping or sewing, while the hosiery blank is in this everted condition. Of course, this separate everting operation adds to the cost of producing the hosiery and this additional handling step increases the likelihood of picks and runs being formed in the hosiery blank.

This separate everting or turning operation may be eliminated by various types -of mechanical turning devices which operate to evert the seamless blank as it is withdrawn from the knitting machine. However, these mechanical devices are expensive to install :and are ditiicult to maintain. Also, if these devices do not operate properly to withdraw the successive :blanks as they are knit, substantial damage to the machine needles, sinkers and other parts will occur.

With the foregoing in mind, it is an object of the present invention to provide a method of knitting seamless hosiery blanks on a circular knitting machine whereby the seamless 'hosiery blanks are withdrawn in an everted condition, and wherein the method is carried out on a conventional knitting machine and does not require the addition of any extra parts to the machine.

According to the present method, the initially knit end of the hosiery blank is held on the dial instrumentalities of the knitting machine while the desired length of blank is knit on the cylinder needles so that the completed blank assumes a folded or two-ply condition inside the needle cylinder with the terminal end being held on the cylinder needles and adjacent the initially knit end which is being held on the dial instrumentalities. The length of the completed blank is thus about one-half the length of `a blank which is knit in the conventional manner. The terminal end of the blank is then released from the cylinder needles to permit the blank to untold and to assume an everted position with the terminal end -at the lowermost end of the blank and the initially knit end being held on the dial instrumentalities. The initially knit end 3,434,308 Patented Feb. 25, 1969 of the blank is then released from the dial instrumentalities and the hosiery blank is withdrawn from the knitting machine in the everted condition.

The present method is particularly adapted for the knitting of ladies sheer hosiery blanks on a line gauge circular knitting machine of the typeequipped with la pneumatic take-down. In this type machine, air currents are drawn downwardly through the needle cylinder to entrain and apply uniform tension to the hosiery blank as it is being knit and these air currents then withdraw the hosiery blank from the machine and convey it to `a collection point, upon completion of the knitting of the hosiery blank. The present method is of particular importance in the knitting of very long hosiery blanks, such as the hosiery blanks utilized in forming panty hose and the like. However, the present method is not limited to the knitting of very long hosiery blanks but is also lapplicable to the knitting of regular length 4hosiery blanks and other types of tubular seamless blanks where it is desirable to withdraw the blanks from the machine in everted condition.

Some of the objects of the invention having been stated, -other objects will appear 'as the description proceeds when taken in connection with the accompanying drawings, in which:

FIGURE l is a vertical sectional view through the upper portion of the needle cylinder of a circular knitting machine with the pneumatic or suction take-down tube extending up inside the needle cylinder and illustrating the manner in which the initially knit end of the tubular knit blank is held on the dial instrumentalities while the blank is being knit by the cylinder needles;

FIGURE 2 is a view `similar to FIGURE 1, illustrating the folded or two-ply condition of the hosiery blank upon completion of the knitting of the desired length, with the terminal end of the hosiery blank being held on the cylinder needles and with the initially knit end being held on the dial instrumentalities;

FIGURE 3 is a somewhat schematic view similar to FIGURES 1 and 2, but showing the condition of the hosiery blank after the terminal end has been released by the cylinder needles and With the initially knit end being held on the dial instrumentalities so that the hosiery blank is in an everted condition;

FIGURE 4 is `a view similar to FIGURE 3, but illustrating the position of the blank after the initially knit end is transferred from the dial instrumentalities to the cylinder needles, in preparation for withdrawal of the hosiery blank; and

FIGURE 5 is a view similar to FIGURE 4, but illustrating the withdrawal of the blank after the initially knit end is released from the cylinder needles.

IThe present method may be used with any of a number of dilferent types of circular hosiery knitting machines which are currently in use, or with new knitting machines having a set of cylinder needles and a set of dial instrumentalities. The circular knitting machine may be of a single-feed or multiple-feed type :and the dial instrumentali-ties may be in the form of the usual transfer jacks or dial bits which are normally employed .to form the turned welt on hosiery or they lmay be in other suitable forms, such as hook or slider elements, llatch needles, or other devices which yare capable of holding loops for a predetermined length of time.

The present invention is shown in :association with a four-feed machine known as a Reading Mark 1V hosiery knitting machine and only those portions of the machine are illustrated and described that are believed -to be necessary to an understanding of the invention. Reference may be made to the parts catalogue published by Textile Machine Works, Reading, Pa., and entitled Four-Feed 3 Ladies Seamless Hosiery Machine for a disclosure of the remaining parts of the machine.

As illustrated in FIGURES Il and 2, the machine includes a needle cylinder having the usual slots in which a set or series of cylinder needles 11 is supported for vertical movement. Sinkers 12 are supported in a grooved sinker bed 13 and are moved in a radial direction by conventional cams, not shown, supported in a sinker cap 14. A dial 15 is supported ladjacent the upper end of the needle cylinder 10 and supports transfer jacks 16 for rotation with the cylinder needles 11 and for radial movement. Conventional cams in the dial 15 control the radial movement of the transfer jacks 16 in a manner to be presently described. As is well-known, the transfer jacks 16 are provided with an upwardly curved outer hooked portion which is capable of receiving and holding a yarn loop and an opening through which a cylinder needle may pass -to transfer the held loop to the cylinder needle.

During the conventional knitt-ing of hosiery blanks on this type of circular knitting machine, the transfer jacks 16 are normally used to form a turned welt, in a wellknown manner. In this conventional knitting method, the yarn is initially fed to alternate cylinder needles r11 to form a make-up and then the transfer jacks 16 are moved outwardly to pick up a loop above the intervening inactive cylinder needles. These loops are transferred to the cylinder needles upon completion of the knitting of the turned welt. The knitting machine is usually provided with half as many transfer jacks 16 as there are cylinder needles 11. For example, in a 400 needle machine, 200 transfer jacks 16 are provided and they are spaced above and in alignment with every other cylinder needle 11.

The pneumatic take-down system of the knitting machine includes a funnel-shaped mouthpiece 17 which is supported yat its upper end at the upper end of the needle cylinder 10. The lower end of the mouthpiece 17 is connected to the upper end of 4a suction tube 18 which is suitably supported inside the needle cylinder 10. The suction tube 18 is provided with a bend or turn, as indicated at 20 in FIGURES l and 2, which is positioned near the floor on which the machine sets. When the hosiery blank is completed and released from the knitting needles, the suc-tion in the tube 18 withdraws the completed hosiery blank and conveys it to a suitable collection chamber, not shown, which is positioned in a convenient location for -removal by the operator, as desired.

The pneumatic take-down system draws air inwardly between the dial 15 and the upper end of the needle cylinder 10 -so that suction air currents are created in the suction tube -18 to thereby exert a uniform tension on the blank and draw the same downwardly in the needle cylinder 10 as it is being knit. In the conventional method of knitting, the hosiery blank is drawn straight down the suction tube 18 as knitting progresses and the blank is withdrawn in right-side-out condition.

When the length of the straight portion of the suction tube 18 is greater than the length of the hosiery blank to be formed on the machine, the hosiery blank may rotate with the needle cylinder without undue twisting of the fabric. In most circular knitting machines currently on the market, this straight section of the suction tube 18 is long enough that the lower end of `a regular length hosiery blank will not reach the bend 20 before it is discharged so that excessive twisting of the fabric does not occur. However, when knitting extra long hosiery blanks, such as those used to form panty hose, the lower end of the long hosiery blank extends into the bend 20 and excessive twisting of the fabric results. It is diflicult to subsequently untwist these tightly twisted blanks and the untwisting of the blanks results in a high number of picks being formed in the fabric.

By use of the present method, very long panty hose blanks may be knit without any substantial amount of twisting of the blank because the full length of the blank does not extend into the suction tube 18 during any substantial portion of the knitting operation. Even upon completion of the knitting of the hosiery blank, the blank extends downwardly in 4the suction ltube 18 a distance equal to substantially half the overall length of the hosiery blank, as shown in FIGURE 2. Therefore, even when the present method is practiced on machines particularly adapted for knitting regular length hosiery blanks, it is possible to knit extra long panty hose blanks without objectionable twisting of the blanks.

In accordance with the present method, the hosiery blank, indicated at B, is knit by initially feeding yarn to alternate cylinder needles 11 to form a make-up of one or two courses. The transfer jacks 16 then move outwardly above the inactive cylinder needles to pick up loops of yarn in their hooked ends for one course. The transfer jacks 16 are then drawn inwardly, holding the yarn loops and the initially knit end E-1 of the blank thereon. All cylinder needles 11 then knit the remainder of the hosiery blank B while the initially knit end E-1 of the hosiery blank is held on the transfer jacks 16, as illustrated in FIGURES l and 2. The air currents passing downwardly through the suction tube 18 entrain the knit fabric and apply uniform downward tension on the fabric as it is being knit. Since the initially knit end E-l is held on the transfer jacks 16, the hosiery blank is formed in a folded or two-ply condition, as illustrated in FIGURES l and 2, and upon completion of the knitting of the desired length of hosiery blank, the terminal end E-Z of the hosiery blank is held on the cylinder needles 11 and closely adjacent the initially knit end E-l (FIGURE 2).

The terminal end E-2 is then released from the cylinder needles, preferably by moving the yarn feeding lingers to an inactive position so that the cylinder needles shed the fabric therefrom and the air currents in the suction tube 18 cause the outer ply or fold of the blank to be drawn down in the suction tube 18 with the terminal end E2 at the lowermost end of the blank B, as shown in FIGURE 3, and with the initially knit end E-l still being held on the transfer jacks 16. At this point, the hosiery blank B is in a completely everted condition and will be withdrawn and carried through the suction tube 18 to the collection point, not shown, upon release of the initially knit end E-l from the transfer jacks 16.

This release of the blank is preferably accomplished by moving the transfer jacks outwardly to transfer position so that the loops held thereby are transferred back to the corresponding cylinder needles 11. This transfer is accomplished in the conventional manner by moving the transfer jacks outwardly and raising the cylinder needles through the loops held on the transfer points and then withdrawing the transfer jacks so that the loops are transferred to the cylinder needles 11. In FIGURE 4 the initially knit end E-1 is shown being held on the cylinder needles 11 even though, in practice, this condition would not occur because the initially knit end E-l is shed from the cylinder needles 11 soon after the yarn loops are transferred to the cylinder needles. The yarn loops `are shed from the cylinder needles because no yarn is being fed to the needles and as soon as they pass through a knitting station, the transferred yarn loops will be shed.

Thus, the complete eversion and release of the blank, as illustrated in FIGURES '2-5, requires less than a single rotation of the needle cylinder 10 on a four-feed knitting machine. Therefore, even though the suction take-up may draw the terminal end E-Z around a bend in the suction tube 18 when this terminal end is released from the cylinder needles 11, no substantial amount of twisting of the hosiery blank will occur because no substantial rotation of the cylinder 10 and dial 15 occurs between the time the terminal end E-2 is released from the cylinder needles 11 and the release of the blank by the cylinder needles.

As soon as the initially knit end E-1 is released from the cylinder needles, as shown in FIGURE 5, the pneumatic take-down system withdraws the hosiery blank from the knitting machine and deposits it in the usual collection chamber, not shown. The everted hosiery blank is then in condition that the toe end may be closed, either by a sewing or looping operation. In the case of panty hose blanks, the everted blank is ready to have the toe end closed, and to be slit in a walewise direction so that it may be sewed to another slit blank to form the panty hose.

The hosiery blank is illustrated as being a substantially straight tube which is knit throughout with continuous rotation of the needle cylinder; however, it is to be understood that conventional reciprocatorily knit heel and/or toe pockets may be formed in the blank, if desired. Also, selected portions of the blank B may be reinforced and any desired stitch construction may be utilized in knitting the hosiery blank B.

The hosiery blank is illustrated and described as being knit without a turned welt portion on the initially knit end E-l. However, a turned welt portion may be formed on the blank, if desired. The turned welt may be formed in the usual manner and the transfer jacks will again be moved out over alternate inactive needles to pick up yarn loops and hold them while the leg and foot portions are being knit on the cylinder needles. The terminal end portion is then released from the cylinder needles to complete the eversion and the hosiery blank is withdrawn by releasing the held loops from the transfer jacks. Thus, the turned welt portion is knit prior to the formation of the initially knit edge and is held under the dial where it does not interfere with the knitting and eversion of the hosiery blank.

In the drawings and specification there has been set forth a preferred embodiment of the invention and although specic terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.

I claim:

1. A method of knitting a seamless hosiery blank on a circular knitting machine having a cylinder, a series of cylinder needles supported in said cylinder, and a series of dial instrumentalities operable in cooperation with said cylinder needles, said method comprising the steps of:

(a) forming an initially knit end of the hosiery blank and holding the same on said dial instrumentalities while knitting the remaining length of said blank on said cylinder needles to form a terminal end thereon, said blank being formed in folded condition with said terminal end being held on said cylinder needles and adjacent said initially knit end which is being held on said dial instrumentalities,

(b) releasing said terminal end from said cylinder needles to permit said blank to unfold and assume an everted condition with said terminal end at the lowermost end of said blank,

(c) releasing said initially knit end of said blank from said dial instrumentalities, and

(d) withdrawing said blank from the machine in everted condition.

2. A method according to claim 1 wherein said dial instrumentalities comprise transfer jacks, and wherein said releasing step (c) includes:

(1) transferring said initially knit end from said transfer jacks to said cylinder needles, and

(2) shedding said initially knit end from said cylinder needles.

3. A method according to claim 1 wherein said machine includes pneumatic take-down means for tensioning said blank as it is knit, and wherein said withdrawing step (d) is accomplished by means of said pneumatic take-down means.

4. A method according to claim 3 wherein the unfolding of said blank is accomplished by means of said pneumatic take-down means following the releasing of said terminal end from said cylinder needles.

S. A method of knitting a seamless hosiery blank on a circular knitting machine having a cylinder, a series 0f cylinder needles supported in said cylinder, and a transfer jack aligned with alternate cylinder needles, said method comprising the steps of (a) feeding yarn to and forming a make-up on intervening cylinder needles,

(b) feeding yarn to intervening cylinder needles and to said transfer jacks to form a transfer course,

(c) holding said transfer course on said transfer jacks while knitting the remaining length of said blank on said cylinder needles to form a terminal end thereon, said blank being formed in folded condition with said terminal end being held on said cylinder needles and adjacent said transfer course which is `being held on said transfer jacks,

(d) stopping the feeding of yarn to said cylinder needles to release said terminal end from said cylinder needles and to permit said blank to unfold and assume an everted condition with said terminal end at the lowermost end of said blank (e) releasing said transfer course from said transfer jacks, and

(f) withdrawing said blank from the machine in everted condition.

6. A method according to claim S wherein said releasing step (c) includes:

( l) transferring said transfer course from said transfer jacks to said alternate cylinder needles, and

(2) shedding said transfer course from said alternate cylinder needles.

7. A method of knitting a seamless hosiery blank on a circular knitting machine having a cylinder, a series of cylinder needles supported in said cylinder, and a series of dial instrumentalities operable in cooperation with said cylinder needles, said method comprising the steps of:

(a) knitting successive courses of stitch loops to form a first end portion of said blank,

(b) holding said rst end portion on said dial instrumentalities while knitting the remaining length of said blank on said cylinder needles,

(c) releasing said blank from said cylinder needles,

(d) drawing said blank downwardly to fully extended position, and

(e) releasing said first end portion from said dial instrumentalities whereby said blank is withdrawn in everted condition.

References Cited UNITED STATES PATENTS 2,709,352 5/ 1955 Lawson 66-149 2,975,622 3/ 1961 Booton 66-149 3,392,551 7/ 1968 Tenconi 66--149 FOREIGN PATENTS 1,411,420 8/ 1965 France.

34,117 12/ 1964 Germany. 955,184 4/ 1964 Great Britain. 622,155 6/ 1961 Italy.

RGNALD FELDBAUM, Primary Examiner. 

